Composite label and method of making

ABSTRACT

A method for making labels comprising providing a plastic substrate layer and a paper substrate layer. The paper substrate layer comprises a printed display information sheet, wherein the printed display information sheet comprises a plurality of display information tags arranged in an array. The plastic substrate layer is coupled to each of the rows of display information tags within a first portion of the display information tags to form a composite substrate row. A first line of perforations is cut into a width of the composite substrate at one or more first spaced intervals, a length of the first spaced intervals being defined by a length of the display information tags. A a second line of perforations is cut into a width of the composite substrate at one or more second spaced intervals, a length of the second spaced intervals being defined by a height of the display information tags.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/296,125 filed on Mar. 7, 2019, entitled “Composite Label and Methodof Making”, which is a divisional of U.S. patent application Ser. No.14/937,201 filed on Nov. 10, 2015, now U.S. Pat. No. 10,276,069,entitled “Composite Label and Method of Making” which claims the benefitof U.S. Provisional Patent Application No. 62/077,368 filed Nov. 10,2014 entitled “Cool-Clips Label”, each of which is incorporated byreference herein in their entirety.

FIELD OF THE INVENTION

The present invention generally relates to labels for a shelf edge. Inparticular embodiments, the invention relates to labels suitable for usein a cold environment, such as the refrigerated and frozen departmentsof a grocery store, and methods for making the same.

BACKGROUND OF THE INVENTION

Traditional pressure sensitive adhesive tags (also referred to herein aslabels) do not adhere well to the shelf edge in the refrigerated andfrozen food departments of a store due to the moisture and cold (e.g.,sub-zero) temperatures present in such environments. To overcome thisproblem, a tag is adhered to a plastic chip, which is clipped into themolding on the top and bottom portions of the shelf edge. The processfor adhering a tag to a plastic chip in this manner is manual-laborintensive.

BRIEF SUMMARY OF THE INVENTION

One embodiment includes a method of making a plurality of labelscomprising providing a plastic substrate layer; providing a papersubstrate layer, wherein the paper substrate layer comprises a printeddisplay information sheet, wherein the printed display information sheetcomprises a plurality of display information tags arranged in an array,the array having at least two columns and at least two rows of displayinformation tags, wherein each of the display information tags comprisesa first portion and a second portion; coupling the plastic substratelayer to each of the rows of display information tags within the firstportion of the display information tags to form a composite substraterow; cutting a first line of perforations into a width of the compositesubstrate at one or more first spaced intervals, a length of the firstspaced intervals being defined by a length of each of the displayinformation tags; and cutting a second line of perforations into a widthof the composite substrate at one or more second spaced intervals, alength of the second spaced intervals being defined by a height of eachof the display information tags.

In certain embodiments of the method, each of the composite substraterows comprises a first portion that includes the first portion of thedisplay information tag and a second portion that includes the secondportion of the display information tag, and wherein cutting theperforations comprises cutting first perforations in the first portionof the composite substrate row and cutting second perforations in thesecond portion of the composite substrate row, wherein the firstperforations are larger in height than the second perforations. In someembodiments, the first perforations are approximately 0.5650 inches inheight. In other embodiments, the second perforations are approximately0.04 inches in height. In still other embodiments, a length of the firstspaced intervals is in a range of 1 inch to 1¼ inch.

A further embodiment includes a method of making a sheet of connectedlabels comprising providing a paper substrate having a plurality ofdisplay information tags arranged in an array, the array having at leasttwo columns of display information tags, wherein each of the displayinformation tags comprises a first portion and a second portion;coupling, directly or indirectly, a strip of composite material to thepaper substrate to form at least one composite substrate row containingthe first portion of the display information tags and at least one papersubstrate row containing the second portion of the display informationtags; and cutting a plurality of perforations through the at least onepaper substrate row and the at least one composite substrate row betweeneach adjacent display information tag to define individual labels.

In certain embodiments of the method, a height of each perforationextending through the at least one composite substrate row is largerthan a height of each perforation extending through the at least onepaper substrate row.

A further embodiment is directed to a sheet of labels comprising atleast one first strip of a first material extending in a first directionand having a bottom surface; at least one second strip of a secondmaterial extending in the first direction and having a top surfacecoupled with the bottom surface of the at least one first strip, thesecond material being stiffer than the first material; and a pluralityof perforations forming a plurality of perforated lines extendingthrough the at least one first strip and the at least one second stripin a second direction generally perpendicular to the first direction.

In certain embodiments of the sheet of labels, the plurality ofperforations extending through the at least one second strip are longerthan the plurality of perforations extending through the at least onefirst strip.

A further embodiment is directed to a method of making a plurality oflabels comprising applying an adhesive strip to a top surface of aplastic substrate to form a plastic substrate layer; printing displayinformation on a top surface of a paper substrate; affixing a firstlayer of lamination material to a bottom surface of the paper substrateand affixing a second layer of lamination material to the top surface ofthe paper substrate to form a display information sheet, wherein thedisplay information sheet comprises a plurality of display informationtags arranged in an array, the array having at least two columns and atleast two rows of display information tags, wherein each of the displayinformation tags comprises a first portion and a second portion; foreach row of display information tags, affixing the adhesive strip to thefirst layer of the lamination material within the first portion of thedisplay information tags in the row to form a composite substrate row;cutting a first line of perforations into a width of the compositesubstrate at one or more first spaced intervals, a length of the firstspaced intervals being defined by a length of each of the displayinformation tags; and cutting a second line of perforations into a widthof the composite substrate at one or more second spaced intervals, alength of the second spaced intervals being defined by a height of eachof the display information tags.

In certain embodiments of the method, each of the composite substraterows comprises a first portion that includes the first portion of thedisplay information tag and a second portion that includes the secondportion of the display information tag; and wherein cutting the firstline of perforations comprises cutting first perforations in the firstportion of the composite substrate row and cutting second perforationsin the second portion of the composite substrate row, wherein the firstperforations are larger in height than the second perforations. In someembodiments, the first perforations are approximately 0.5650 inches inheight. In other embodiments, the second perforations are approximately0.04 inches in height. In still further embodiments, a length of thefirst spaced intervals is in a range of 1 inch to 1¼ inch. In otherembodiments, a height of the adhesive strip is approximately centered ina height of the plastic substrate. In other embodiments, a height of theadhesive strip is in the range of ½ inch to ⅝ inch. In otherembodiments, a height of the plastic substrate is about 1¼ inch. Infurther embodiments, a width of the plastic substrate is in the range of0.0007 inch to 0.001 inch.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofembodiments of the composite label and method, will be better understoodwhen read in conjunction with the appended drawings of an exemplaryembodiment. It should be understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown.

In the drawings:

FIG. 1 is a side and exploded view of a composite substrate comprising apaper substrate layer and a plastic substrate layer in accordance withan exemplary embodiment of the present invention;

FIG. 2A is a perspective view of the plastic substrate layer shown inFIG. 1;

FIG. 2B is a perspective view of the paper substrate layer shown in FIG.1;

FIG. 3 is a top view of an individual label in accordance with anexemplary embodiment of the present invention;

FIG. 4A is a top view of a sheet of labels in accordance with anexemplary embodiment of the present invention;

FIG. 4B is an enlarged view of a portion of FIG. 4A;

FIG. 5A is a bottom view of the sheet of labels;

FIG. 5B is an enlarged view of a portion of FIG. 5A; and

FIG. 6 is a side view of an individual label clipped into a shelf edgein accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Described herein are labels that are suitable for use in a coldenvironment, such as the refrigerated and frozen food departments of astore, and methods of making the same. Such labels are similar totraditional labels in terms of the paper, laminate and certain aspectsof the manufacturing process but, in place of a pressure sensitiveadhesive tape used to secure the label to the shelf, a plastic substrateto which adhesive has been affixed is secured to the paper tag, inexemplary embodiments. New processes are required to automate theprocess of coupling the plastic substrate to the paper tag, as describedmore fully herein.

FIG. 1 is a side and exploded view of a composite substrate 1000comprising a paper substrate layer 100 and a plastic substrate layer 10,in accordance with an exemplary embodiment of the present invention.Paper substrate layer 100, in certain exemplary embodiments, comprises aprinted display information sheet 80, which includes display informationprinted thereon (e.g., bar codes, prices, unit prices, sale information,advertisements), a first layer of lamination material 82 and a secondlayer of lamination material 81. Plastic substrate layer 10, in certainexemplary embodiments, comprises an adhesive strip 15 and a plasticsubstrate 20. Paper substrate layer 100 is formed of a first material(e.g., paper which, in one embodiment, is laminated on the top andbottom) and plastic substrate layer 10 is formed of a second material(e.g., plastic). The second material is stiffer than the first material.The second material may be supplied in a roll form for coupling to thefirst material. In some embodiments, paper substrate layer 100 is notformed from paper laminated on the top and bottom. For example, in otherembodiments, paper substrate layer 100 is formed from paper alone (nolaminate) or from a vinyl material (or poly, foil etc.) with displayinformation printed on the vinyl material.

FIG. 2A is a perspective view of the plastic substrate layer 10 inaccordance with an exemplary embodiment of the present invention.Plastic substrate layer 10 includes plastic substrate 20 with adhesivestrip 15 affixed to the top. Adhesive strip 15 is used to couple plasticsubstrate 20 to paper substrate layer 100. In the exemplary embodiment,adhesive strip 15 is adhered to the bottom side of plastic substratelayer 10, e.g., first layer of lamination material 82. Plastic substratelayer 10 is associated with a width W₁. W₁ is in the range of 0.0007 to0.001 inches, in an exemplary embodiment. The plastic substrate 20 isassociated with a height H₁ and the adhesive strip 15 is associated witha height H₂. H₁ is, in an exemplary embodiment, about 1¼ inches. H₂ is,in an exemplary embodiment, ½ to ⅝ inches. The adhesive strip 15 issubstantially centered within the height of the plastic substrate H₁, inan exemplary embodiment.

FIG. 2B is a perspective view of the paper substrate layer 100. Papersubstrate layer 100 is associated with a width W₂.

While in the illustrated embodiment plastic substrate layer 10 iscoupled to the underside of paper substrate layer 100 using adhesivestrip 15, other methods of coupling plastic substrate layer 10 to papersubstrate layer 100 are possible.

FIG. 4A is a top view of the composite substrate 1000 in accordance withan exemplary embodiment of the present invention. Composite substrate1000 includes at least two rows and at least two columns and includes atop edge 110, a bottom edge 120, left edge 140 and right edge 130.Composite substrate 1000 comprises a plurality of individual displayinformation tags 50 arranged in an array of rows R and columns C. Theindividual display information tags 50 are formed from compositesubstrate 1000 by lines of perforations 68 cut along the rows and linesof perforations 60 and 61 cut along the columns, as described in moredetail with reference to FIGS. 4B and 5B. Each display information tag50 is associated with a height H₃ and length L₁. In an exemplaryembodiment, L₁ is approximately 1 inch to 1¼ inch. Each column isassociated with a height H₄ and a length, the length of the columncoinciding with the length of a single display information tag 50, L₁.Each row is associated with a length L₂, which is the length ofcomposite substrate 1000, and a height, which is the height of a singledisplay information tag H₃. In production, composite substrate 1000, insome embodiments, is cut from a larger sheet of composite material(i.e., knife cuts in the larger sheet of material result in clean edges,namely top edge 110, bottom edge 120, left edge 140 and rights edge130). A top edge of plastic substrate layer 10 is generally co-extensivewith top edge 110.

FIG. 3 is a top view of an individual display information tag 50 inaccordance with an exemplary embodiment of the present invention.Display information tag 50 includes a first portion 51 and a secondportion 52. First portion 51 and second portion 52 may be separated by aline of perforations 63, in some embodiments. As shown in FIG. 4A, eachrow of composite substrate 100 may include a line of perforations 63 aand 63 b. In other embodiments, there is no physical indication ofseparation (e.g., no line of perforations 63) between first portion 51and second portion 52. Each display information tag 50 may includeprinted indicia (e.g., printed on printed display information sheet 80),including a bar code, price, unit price, advertisements or saleinformation. In exemplary embodiments, the bar code, price and unitprice is contained within first portion 51 and advertisements and saleinformation is contained within second portion 52. However, otherconfigurations are within the scope of the present invention.

FIG. 4B is an enlarged view of a portion of FIG. 4A which illustratesthe perforations 60 a and 60 b and 61 a and 61 b cut between adjacentcolumns of composite substrate 1000. Perforations 60 a and 60 b are cutthrough the width of composite substrate (i.e., W₁+W₂) between adjacentcolumns of composite substrate 1000 in the sections that include plasticsubstrate layer 10. Perforations 61 a and 61 b . . . 61 n are cutthrough the width of composite substrate (i.e., W₂) between adjacentcolumns in the sections that do not include plastic substrate layer 10.Between perforations, ties 62 a, 62 b and 62 c remain in the sections ofcomposite substrate 1000 that include plastic substrate layer 10 (aswell in the portion of composite substrate 1000 that does not includeplastic substrate layer 10 between perforations 61 a, 61 b . . . 61 n,although the ties between perforations 61 a, 61 b . . . 61 n are notlabeled in FIG. 4A or 4B), to hold composite substrate 1000 togetherprior to manual separation. In order to separate composite substrate1000 into display information tags 50, it is necessary to manuallyseparate composite substrate 1000 at perforations 60 a, 60 b, 61 a, 61 b. . . 61 n, as well as along perforation line 68. In certain exemplaryembodiments, a height of each of perforations 60 a and 60 b (H_(P1)) isapproximately 0.5650 inches; a height of each of perforations 61 a, 61 b. . . 61 n (H_(P2)) is approximately 0.040 inches; and a height (H_(T))of each of ties 62 a, 62 b, 62 c is approximately 0.40 inches, or may be0.02 inches in certain embodiments.

In some embodiments, in order to achieve the perforations, there couldbe a full cut in the plastic material and perforations in the paperportion (referred to as a slit over perf). Perforations 60 a and 60 bcan be full or solid cuts. Ties 62 a, 62 b and 62 c may be included inthe cuts of section plastic substrate layer 10 for strength of thecomposite substrate 1000 for manufacturing and delivery purposes.

FIG. 5A is a bottom view of the composite substrate 1000. In this view,plastic substrate layer 10 is visible, having been coupled to theunderside of paper substrate layer 100. In some embodiments, there is asmall gap (e.g., 1/16 inches; gap not shown in FIG. 5A) between the topedge 110 of the paper substrate layer 100 and the top edge of theplastic substrate layer 10. Perforation 68 is included in the papersubstrate layer 100 for purposes of separating of the individual labels50.

FIG. 5B is an enlarged view of a portion of FIG. 5A and is similar toFIG. 4B except that plastic substrate layer 10 is visible and, asdescribed above, in some embodiments, a small portion (e.g., 1/16 inchesof paper substrate layer 100) extends above plastic substrate layer 10,though this portion/gap is not shown.

FIG. 6 is a side view of a display information tag 50 clipped into ashelf edge 5, in accordance with an exemplary embodiment of the presentinvention. First portion 51 of display information tag 50 may becontained within the area of the shelf edge and second portion 52 ofdisplay information tag 50 hangs down from the shelf edge. Plasticsubstrate layer 10 may clip into the top flange 7 and bottom flange 8 ofthe shelf edge.

It will be appreciated by those skilled in the art that changes could bemade to the exemplary embodiments shown and described above withoutdeparting from the broad inventive concepts thereof. It is understood,therefore, that this invention is not limited to the exemplaryembodiments shown and described, but it is intended to covermodifications within the spirit and scope of the present invention asdefined by the claims. For example, specific features of the exemplaryembodiments may or may not be part of the claimed invention and variousfeatures of the disclosed embodiments may be combined. Unlessspecifically set forth herein, the terms “a,” “an” and “the” are notlimited to one element but instead should be read as meaning “at leastone.”

It is to be understood that at least some of the figures anddescriptions of the invention have been simplified to focus on elementsthat are relevant for a clear understanding of the invention, whileeliminating, for purposes of clarity, other elements that those ofordinary skill in the art will appreciate may also comprise a portion ofthe invention. However, because such elements are well known in the art,and because they do not necessarily facilitate a better understanding ofthe invention, a description of such elements is not provided herein.

Further, to the extent that the methods of the present invention do notrely on the particular order of steps set forth herein, the particularorder of the steps should not be construed as limitation on the claims.Any claims directed to the methods of the present invention should notbe limited to the performance of their steps in the order written, andone skilled in the art can readily appreciate that the steps may bevaried and still remain within the spirit and scope of the presentinvention.

We claim:
 1. A sheet of labels comprising: at least one first strip of afirst material having a length extending in a first direction and havinga bottom surface; at least one second strip of a second material havinga length extending in the first direction and having a top surfacecoupled with the bottom surface of the at least one first strip, thesecond material being stiffer than the first material; and a pluralityof perforations forming a plurality of perforated lines, each perforatedline of the plurality of perforated lines extending through the at leastone first strip and the at least one second strip in a second direction,the second direction extending along a height of the at least one firststrip and the at least one second strip generally perpendicular to thefirst direction.
 2. The sheet of labels of claim 1, wherein theplurality of perforations extending through both the at least one firststrip and at least one second strip are longer in the second directionthan the plurality of perforations extending through only the at leastone first strip.
 3. The sheet of labels of claim 2, wherein theplurality of perforations which extend through both the at least onefirst strip and the at least one second strip are approximately 0.5650inches in length along the second direction.
 4. The sheet of labels ofclaim 2, wherein the plurality of perforations which extend through onlythe at least one first strip are approximately 0.04 inches in lengthalong the second direction.
 5. The sheet of labels of claim 1, whereinthe coupling of the at least one first strip and at least one secondstrip forms a display information sheet, the display information sheetcomprising: a plurality of display information tags arranged in anarray, the array having at least two columns and at least two rows ofdisplay information tags, wherein each display information tag of theplurality of display information tags comprises a first portion and asecond portion.
 6. The sheet of labels of claim 5 further comprising: asecond plurality of perforations forming a second plurality ofperforated lines, the second plurality of perforations extending in thefirst direction along a width of the at least one first strip and the atleast one second strip.
 7. The sheet of labels of claim 1, wherein theat least one second strip is coupled to the bottom surface of the atleast one first strip by an adhesive strip.
 8. The sheet of labels ofclaim 1, wherein the at least one first strip has a top surfaceincluding printed display information.
 9. The sheet of labels of claim1, wherein the at least one first strip includes at least two firststrips.
 10. The sheet of labels of claim 1, wherein the at least onefirst strip is comprised of paper and the at least one second strip iscomprised of a plastic material.
 11. The sheet of labels of claim 1,wherein the at least one second strip includes at least two secondstrips.
 12. The sheet of labels of claim 5, wherein the plurality ofperforated lines are at one or more first spaced intervals having alength defined by the length of each of the display information tags.